Wire spool



Feb. 5, 1957 J. J. MITNlcK 2,780,420

WIRE SPOOL K Filed ,July 21, 1954 2 Sheets-Sheet 1 lugs J. J. MITNICK Feb. s, 1957 WIRE spoor.

2 Sheets-Sheet 2 Filed July 21, 1954 United States Patent WIRE sPooL Jacob J. Mitnick, Highland Park, Ill., assignor to Magnet Wire, Inc., Chicago, Ill.

Application July 21, 1954, Serial No. 444,756

2 Claims. (Cl. 242-123) This invention relates generally to spools, and more particularly is concerned with the construction of a spool for carrying fine wire of the type used in making windings and coils for electrical components such as transformers and ballasts.

Spools of the type here described have two principal purposes, the second of which is perhaps the most important of the two. The rst purpose is to serve as a carrier or storage receptacle for wire. The wire is manufactured and Wound upon spools of this type, and these spools are thereafter stored, and/or transported to the ultimate user. While some users may not require the 2,780,420 Patented Feb. 5, 1957 r' ICC of simple structure and great strength, the provision of a novel method of fabrication and assembly of the spool.

Other objects will become apparent as the description of the invention proceeds, in connection with which there has been illustrated and described a preferred embodiment showing the practical construction of a wire spool utilizing the invention. -Modied forms are also referred to. The description and details of the preferred structure are only by way of example and not limitation.

In the drawings, in which like characters of reference are applied to the same or equivalent parts throughout the several figures of the drawings:

Fig. 1 is a top plan view of the spool embodying the invention.

Fig. 2 is a side elevational view of the spool, which like the other views, do not illustrate the wire or the spool mountings.

Fig. 3 is an enlarged sectional view through the spool taken generally along the line 3-3 of Fig. l and in the indicated direction.

Fig. 4 is a fragmentary enlarged sectional view showing a detail of assembly of the end plate of the spool.

spool thereafter except as a means for carrying the wire,

most users of the tine Wire with which this invention is principally concerned will utilize the same spool for the second purpose which will be mentioned. In the cases where the user purchases the wire in large reels or manufactures his own wire, he will rewind the wire upon this type of spool before using the same.

The second purpose for the spool is to hold and permit feeding of the wire to winding machines. In most winding machines there are provided a plurality of spool mounting spindleswith braking, tensioning, feeding and other functions so that the Wire from the spools is led directly to the winding spindle upon which are formed coils for use in electrical apparatus.

Spools of structure of this invention may be made in large sizes for purposes of carrying heavy cable and rope-they may be several feet in diameter and made out of steel or other tough materials. It is intended primarily, however, that the spools be used for ne wire of the type used in ballasts for uorescent fixtures, such as for example from 16 to 40 gauge, and hence that such spools be of the order of six inches in diameter and made of aluminum and similar light alloys. Itis believed that the maximum of advantages is obtained in this smaller size.

Several objections to prior structures have not been overcome in the prior art, and among these are the lack of combined strength and lightness in weight which it is an important object of the invention to achieve.

Another objection of the prior structures lies in the absence of hub strength which gives rise to likelihood of transverse collapse and denting. The invention contemplates the provision of a novel structure eliminating this in a highly economical and efficient manner.

Prior structures have also been constructed of a great many parts-have been ditiicult to assemble and expensive to manufacture-have not provided sutlicient strength in their end plates-have required added members to prevent crushing or distortion of the end plateshave been so constructed as not to utilize to maximum advantage modern eicient manufacturing processes. All of these disadvantages have been overcome by the invention.

Additional and specific objects of the inventionI are the provision of a novel spool having its hub formed of two opposed identical parts, the provision of a novel web Fig. 5 is a sectional view taken through the spool along the line 5 5 of Fig. 3 and looking in the direction indicated, with portions broken away to show certain details.

Figs. 6 and 7 are fragmentary sectional views through modified forms of the invention, and Fig. 8 is a fragmentary sectional view taken through the core of the form of Fig. 6 along the line 8 8 and in the indicated direction.

Generally the spool is formed of a pair of cup-like halves having annular lips, ledges or extensions aboutV their open ends and provided with seating buttons on their bottom walls. A pair of such cups is arranged bottom to bottom, with the buttons aligned so as to mate, such that the combined assemblage of bottoms gives a central, strong double walled web through the interior of the spool. The sides of the cup-like halves form the hub. A central post or core of appropriate configuration is mounted in the center of the cup-like halves, and the open ends capped in a novel manner with plates suitably seated over the annular. lips, ledges or extensions and engaging the free ends of the post.

Specifically referring to the drawings, the spool is designated generally by the reference character 10 and same has a smooth surfaced hub 11 of relatively large diameter for mounting the wire, end plates of composite construction to be described, and a central hollow cylindrical core 13 by means of which the spool 10 may be mounted upon a suitable spindle (not shown) for use.

It will be seen that the hub 11 and the interior faces of the end plates 12 are formed of a pair of cup-like members 15 and 16 which are of identical structure except secured one to the other bottom to bottom. The designations 15 and 16 are merely to enable reference to upper and lower cups, as they will be hereinafter termed, for purposes of explanation. Each of the cups 15 and 16 comprises a bottom wall 18, an integrally formed cylindrical side wall 19, and an annular ledge or extension 21 at the` open end of the cup. Each of the bottom walls has a pair of upset buttons 23 and a pair of perforations 25 whose diameter and form is such as to matingly engage with similar buttons.

The buttons 23 and perforations 25 are spaced 90 apart about the bottom wall 18 of each cup 15 and 16, and -radially equidistant from the axis of the cups and hence the axis of the spool 10, as will be apparent. The buttons protrude outwardly of the respective cups so that they may engage in the perforations 25 of the facing wall 18. Since there are two buttons 23 and two perforations 25 identically placed in each bottom wall, the cups are identical and may be made from the precise same die, by

drawing,` the same in vthe, conventional` punch press. I n assembling the cups and 1,6, they are rotated one relative to the other, either 90 or 180 prior to assembly, dependinarupon"whethenthebutwas; 25...@ perforafions 23) are placed 20 or 1.807 fr-ornorre'another. h

Asfseenin Fig: 5, thejbottom view'ofythe`- Wall Altof thelowercup lreveals that there is a buf-ton'fZ formed on th'e left ,ando'n the bottom (as ,viewed in Fig.'5)- of the wall"18,-while a perforation 25 onthe right andanother on the top'l receive" the buttons 23' of.` the wall 18 of the cup1 5: Actually in this view one' cannotsee the buttons ofthe wall 18 of the lower cup-` 16 because they` areformed' throughthje upsetting-of metal from the wall. Allthat is visible at -thje location of each button isa cylindrical depression, which is designated 23'.y

This v'typeof-construction'requires that the cupsl i5 and 16 be rotated 180 relative one another before assembly.

With the "cupsarranged as"shown`in the drawings, and before' any' other step1V isltakenfin the assembly' of the spool 10, the bottom walls 18-18 are spot-weldedto= gether atcircumferentially spaced v'.points" indicated at'27. This' joins thetwo'walls int'oiadoub-leiweblor partition which for reference can be collectivelyfdesignated`31. Thisisth'e principal constructionalfeature of the spool since 'it provides'great strength and' resistance :to crushing in the center ofthe hub 11 ywithout'w'eight of consequence, and without'any'f complex structures. Where the cups 15"and16 meet there may be avslight seam32, th'e size of w'hich depends upon the radius 'of the 'corner of the cups. Depending onth'e'size ofiwire'tobe'wound upon `the spool 1t?, thisvseam'rrray" or may not be" ground smooth, or filled with any` suitable filler such as plastic, vsolder-or the like.

At the centerof each lof thelwall's 18 theie is kva circular opening, the twor openings combiningtoform'apassage# way 33 the'di'anieter of whichfis `such as to fit the central postor'core closely,I butslidingly." Three diiferent types of cores designated generally`l13, 36V and'37 arev illus-" tratedrespectivelyfin Figs.^3,' 6'aud 7,bu`tthat"ofl Fig'. 3 is preferred.v

Afterhe assembly of the cups 15 arid 16,?th'e V'coreis inserted' into the"pass`agev'vay 33. This core consists of an"elongate" hollow memberv 40 of generally cylindrical formation, butjhaving av centrally located annular bulge 4lA formed thereinja'nd endbnlges 42 andff43. Th'end bulges form shoulders 'such vasshwn at'f45, for example' and prior to assemblyof th'eend p lat'el th'e free ends47 off-the core 13 extend axiallyfrom the* shoulders 45'as indicated at'47 bybroken lines" in: Fig.V '3.' The' forma'f tionfdescribed provides'a'considerable'bearing 'sp''c'ealon'g the length of the core, defined by -two cylindricalV elongate sections Jai'rdtvvoshort sectibrismlgat"theends.' Thus a spindlejor shaft (notshown) has plenty'ofsifalce'either for bearing purposes or Yforl frictionali engagement purposes.` Like-wisr-,v the .end-sections"- 4l9`l provxdelgood'sup# port `forv someftype's of conical 'clamping spindlestht` are used on windin'g machines."

As will bis Seenffrem' the drawings, tascres'nafse andl 37 in each case are'jfoi'med'of identical "halves," pro cation, for economy'in priodiictio'njand'prbvides n Idiffic'ultiesl in'assernfilyl`v Since the structure' ofthe' spool is such that all parts are 'securely'f'h'eld in 'asselmbled"duela-l ticnship, therefisc no nedfor'vieldingeth:twohalves of' each" core together although'jif-desiredthis ma The notches SZaretypicalof the 'ends of lc'ylindrical 'meni-l 54. The extensions o1" ledgesy 21 'are'.also Vcri-planar withI the shoulders 45, -Sothat theymay together support the capping plate 56. The extensions 21 are each provided with a pair of upset protuberances or Ibuttons 57 diametrically arranged. The capping plate is a disc of dimension to tit inside the diameter of the extensions or ledges 21 leaving a considerable overlap. The edge of the capping plate 56 is provided with` a'downwardly oifset, continuous ange 59 whereby the resulting formation provides a strengthening annular bend 60 resisting distortion of the end plate 12. Radially inward of thenbend k60 there is provided an inwardly directed circumferential crimp 62 which forms another strengthening formation.

Each `0f the formations are pressed 'inwardly an amount equal approximately to the thickness of the capping plate 56 so that when placed up'on the extensions 21, the flanges 59 and the inner bulges of the crimps 60 rest upon the face of the extension 21 with which the respective capping plate is associated. On oppositeA sides of the center, in the crimps 62 there are providedwperforations Pftwllerich are radially and circumferentiallly aligned `with the buttons 57 so that whenassembled upon the extensions 21,the capping plates 56 will seat perfectly Icoaxially with the remainder ofthe assembled parts. y n v At its center, `each of the capping plates 56 has a large opening 66 which is surrounded by' an inwardly offset an-y nular flange 67 of the samev formation as the flange l59.; The opening snugly tits the' core Yltatthe` sections 49 and'hence the 'flangesvrest upon th'eshouldersS. ,When they assembly step which consists of placing-ithe plate's56 upon the extensions'ZI is carriedotVall of the edges are extended, and the-core ends 47 are not crimped. After assembly, the rims 54fai'e forir'led'by` crimping the portions` 54' over andV upon the nges 55?,l andA the rounded `core ends 47 are formed bycrimping'thefportions 47' over and upon the flanges 67. Obviously, thro'ughthe use of suitable dies'an'd fixtures, this operation can, be a simple an'dsp'eedyone. The" end plates mayhave openings 69 to cooperate'with theI usual offset spindle pin (not shown). v

It'pwill be seen from the description that'there is no need to provide' castings of anykind;` that'the're are only siX parts which includes the two halvesI of the core 35i that all of the parts are simple stampings or drawings; that they are assembledthrough the useof'seating means which prevents any' error -or rnisalignrnentfof the parts; thatnthefonly fastening means c'ori'sistsfof 4a few welds aboututhe'v web 31, and these welds are intheV interior of the spool; that the remainder of th'e spool is assembled in a simple and etiicient manner',l andi that a'great deal of strength through'the 'use of 'ingenious arrangement of the4 parts has been built vinto the' spool without using' excessivematerial. v Y. l

y In addition, the' resulting ,articlev4 is` capable of( withstanding excessive abuse without being the 'worse for the wear because of thenovel structure.

With respect to the core 'structures illustrated in Figs. 6, 7 'andr8,r Figs. v6 and 8' representa structure in which, instead of a` formed, core `13', the'corfe' 36 is'i'ma'de up of a center uniformly cylixidrical'me'rnber'ydwhichfinay be formed of a pair of identicalhalves abut'ted at'71f'. The sur'fface on the interior i s thus' continuous, 'free ends 72, are cr1mpeduover as are ,the'nends' 47in the cy'rfe 35.l In order't'o l'p/rovid'efa sl'loulderforthe'support4 of',l the flangesn67, an inner telcscopingsleevejd,'is disposed 'about the' member 70,' the" length thereof being. the distance between opposing ilanges 67. I v

Fig. 7 eliminates the s leeve`7l` bylpro"v di f the member 78"((whieh may seppur) wanen@ format yfis,"siprinrjtj th'eend" formations of the' core 35; y An' inward arnllary criniprprovidesa'shoulder 79'fo`r seating thfe ang'es' 67` andthe 'i 67'se'c`ures th'e capping plates 56. The resltingY corel3`7 has: two 4narroifved Abearing portionsul top and bottom; the diameter of they remainder of the member 78'being greater.

ningover of the freeendsf uponl the flanges',

It is believed that the invention has been fully explained so as to be perfectly clear to those skilled in the art, such that further explanation may be dispensed with, but it is desired to point out that variations in the details such as formation of the parts, size, dimensions and proportions are capable of being made without departing from the spirit or scope of the invention as defined in the appended claims.

What it is desired to secure by Letters Patent of the United States is:

l. A spool for wire comprising, a pair of cups each having cylindrical side walls, a bottom wall with a central opening, and an annular extension on the open ends of the side walls, the bottoms having cooperating seating means for positioning same in juxtaposition with the annular extensions on the opposite ends of the resulting formation, said means comprising a plurality of outwardly protruding button and socket formations and spaced one from the other so as to obtain registery of each button with a socket, means spaced radially inward of the edges of the bottoms rigidly joining said bottoms face to face, an annular capping member having an open center secured to each annular extension, and a hollow core member secured between the open centers and through said central opening, assembled to the spool after joining the cups, but before assembling the capping members, said core having a centrally located annular upstanding bulge and the bottoms are seated on said bulge in the central opening.

2. A spool for wire comprising, a pair of cups each having cylindrical side walls, a bottom wall with a cenJ tral opening, and an annular extension on the open ends of the side walls, the bottoms having cooperating seating means for positioning same in juxtaposition with the annular extensions on the opposite ends of the resulting formation, said means comprising a plurality of outwardly protruding button and socket formations and spaced one from the other so as to obtain registry of each button with a socket, means spaced radially inward of the edges of the bottoms rigidly joining said bottom face to face, an annular capping member having an open center secured to each annular extension, and a hollow core member secured between the open centers and through said central opening, assembled to the spool after joining the cups, but before assembling the capping members, said core having a centrally located annular upstanding bulge and the bottoms are seated on said bulge in the central opening, said core having an upstanding shoulder formation on each free end thereof and the valley portions between said shoulders and bulge provide bearing spaces along the length of the core for engagement with a spindle or shaft inserted in the core.

References Cited in the file of this patent UNITED STATES PATENTS 1,981,809 Mueller Nov. 20, 1934 FOREIGN PATENTS 637,246 Great Britain May 17, 1950 

